Channel-reinforced concrete wall panel system

Abstract

A wall system employing channel-reinforced lightweight precast concrete wall panels. The precast wall panels include a concrete slab, a pair of spaced-apart elongated generally parallel metallic side channels, and a plurality of spaced-apart elongated generally parallel metallic attachment channels. The side channels and attachment channels are partially embedded in the slab and extend substantially perpendicular to one another. Each wall panel can be coupled to a support wall by extending self-tapping screws through metallic wall framing members and the attachment channels at locations where the framing members and attachment channels cross.

1. A lightweight precast wall panel comprising:
 a concrete slab presenting side edges that define an outer perimeter of the slab; 
 a pair of elongated spaced-apart first channels; and 
 a plurality of elongated spaced-apart second channels, 
 said first and second channels being partially embedded in the slab and extending substantially perpendicular to one another, 
 said first and second channels being spaced inwardly from the outer perimeter of the slab, 
 at least some of said second channels being disposed generally between the first channels, 
 each of said channels including a substantially flat cross member and a pair of spaced-apart side members extending from the cross member, 
 said slab presenting a substantially flat inside surface from which the channels project, 
 said cross member being defined along a plane that is at least substantially parallel to the inside surface of the slab, 
 said cross member being spaced from the inside surface of the slab a distance in the range of from about 0.5 to about 3 inches. 
 
   
   
     2. The wall panel according to  claim 1 ,
 said first ad second channels being spaced apart form one another. 
 
   
   
     3. The wall panel according to  claim 1 ,
 said cross member being formed of metal, 
 said cross member having a thickness in the range of from about 0.02 to about 0.1 inches. 
 
   
   
     4. The wall panel according to  claim 1 ,
 each of said cross members of said second channels presenting a respective substantially flat outer channel surface, 
 said outer channel surfaces of said second channels being substantially coplanar. 
 
   
   
     5. A lightweight precast wall panel comprising:
 a concrete slab presenting side edges that define an outer perimeter of the slab; 
 a pair of elongated spaced-apart first channels; and 
 a plurality of elongated spaced-apart second channels, 
 said first and second channels being partially embedded in the slab and extending substantially perpendicular to one another, 
 said first and second channels being spaced inwardly from the outer perimeter of the slab, 
 at least some of said second channels being disposed generally between the first channels, 
 each of said channels including a substantially flat cross member and a pair of spaced-apart side members extending from the cross member, 
 said side members diverging from one another as the side members extend away from the cross member, 
 said side members extending from the cross member at a divergence angle in the range of from about 10 to about 60 degrees. 
 
   
   
     6. A lightweight precast wall panel comprising:
 a concrete slab presenting side edges that define an outer perimeter of the slab; 
 a pair of elongated spaced-apart first channels; and 
 a plurality of elongated spaced-apart second channels, 
 said first and second channels being partially embedded in the slab and extending substantially perpendicular to one another, 
 said first and second channels being spaced inwardly from the outer perimeter of the slab, 
 at least some of said second channels being disposed generally between the first channels, 
 each of said channels including a substantially flat cross member and a pair of spaced-apart side members extending from the cross member, 
 each of said side members being partially embedded in the slab with concrete on both sides of each side member. 
 
   
   
     7. A lightweight precast wall panel comprising:
 a concrete slab; 
 a pair of elongated spaced-apart first channels; and 
 a plurality of elongated spaced-apart second channels, 
 said first and second channels being partially embedded in the slab and extending substantially perpendicular to one another, 
 said first and second channels being spaced apart from one another so that they are not directly connected to one another, 
 at least some of said second channels being disposed generally between the first channels, 
 each of said channels including a substantially flat cross member and a pair of spaced-apart side members extending from the cross member, 
 said slab presenting a substantially flat inside surface from which the channels project, 
 said cross member being defined along a plane that is at least substantially parallel to the inside surface of the slab, 
 said cross member being spaced from the inside surface of the slab a distance in the range of from about 0.5 to about 3 inches. 
 
   
   
     8. The wall panel according to  claim 7 ,
 said cross member being formed of metal, 
 said cross member having a thickness in the range of from about 0.02 to about 0.1 inches. 
 
   
   
     9. The wall panel according to  claim 7 ,
 each of said cross members of said second channels presenting a respective substantially flat outer channel surface, 
 said outer channel surfaces of said second channels being substantially coplanar. 
 
   
   
     10. A lightweight precast wall panel comprising:
 a concrete slab; 
 a pair of elongated spaced-apart first channels; and 
 a plurality of elongated spaced-apart second channels, 
 said first and second channels being partially embedded in the slab and extending substantially perpendicular to one another, 
 said first and second channels being spaced apart from one another so that they are not directly connected to one another, 
 at least some of said second channels being disposed generally between the first channels, 
 each of said channels including a substantially flat cross member and a pair of spaced-apart side members extending from the cross member, 
 said side members diverging from one another as the side members extend away from the cross member, 
 said side members extending from the cross member at a divergence angle in the range of from about 10 to about 60 degrees. 
 
   
   
     11. A lightweight precast wall panel comprising:
 a concrete slab; 
 a pair of elongated spaced-apart first channels; and 
 a plurality of elongated spaced-apart second channels, 
 said first and second channels being partially embedded in the slab and extending substantially perpendicular to one another, 
 said first and second channels being spaced apart from one another so that they are not directly connected to one another, 
 at least some of said second channels being disposed generally between the first channels, 
 each of said channels including a substantially flat cross member and a pair of spaced-apart side members extending from the cross member, 
 each of said side members being partially embedded in the slab with concrete on both sides of each side member. 
 
   
   
     12. The wall panel according to  claim 11 ,
 said slab presenting side edges that define an outer perimeter of the slab, 
 said channels being spaced inwardly from the outer perimeter of the slab.